Mattress having a foam panel which interlocks a spring assembly and a quilted assembly

ABSTRACT

A mattress including a housing having a panel forming a base and a border connected to the panel, wherein the panel and border define a receptacle having a first end and a second end. The mattress further includes a spring assembly positioned on the panel and within the receptacle, wherein the spring assembly comprises a plurality of first and second coils arranged in rows extending continuously from the first end to the second end of the receptacle, wherein the first coils are different in size from the second coils; wherein groups of one or more of the first coils and groups of one or more of the second coils define at least three zones of firmness between the first end and the second end of the receptacle, wherein each of the first and second coils includes a first end and a second end; and wherein the first ends of the first and second coils are disposed adjacent the housing panel and lie in a first plane parallel to the housing panel. The mattress further includes a quilted assembly; and a foam panel disposed between the quilted assembly and the second ends of the first and second coils.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit under 35 U.S.C. §119(e) of the earlier filing date of U.S. Provisional Application Ser. No. 61/285,649 filed on Dec. 11, 2009, the contents of which are hereby incorporated by reference.

FIELD OF THE INVENTION

This application discloses an invention which is related, generally and in various embodiments, to a mattress having a foam panel which interlocks a spring assembly and a quilted assembly.

BACKGROUND OF THE INVENTION

Conventional mattresses are constructed in many different ways to provide uniform or varied firmness along their lengths, such as conventional coil spring mattresses or synthetic foam mattresses. Other mattresses include housings made of synthetic polymer/copolymer plastic material generally formed by upper and lower layers or panels and a peripheral border therebetween. In one type of mattress a spring unit or series of springs are housed within the chamber of the mattress housing. Conventional mattresses utilizing springs can be zoned to provide varying firmness. Typical zoned mattresses are divided into at least three longitudinal zones of differing firmnesses.

BRIEF DESCRIPTION OF THE DRAWINGS

Various embodiments of the invention are described herein in by way of example in conjunction with the following figures, wherein like reference characters designate the same or similar elements.

FIG. 1 illustrates various embodiments of a mattress;

FIG. 2 illustrates various embodiments of a housing of the mattress of FIG. 1;

FIGS. 3 and 4 illustrate various embodiments of a spring assembly of the mattress of FIG. 1;

FIGS. 5-9 illustrate different arrangements of first and second coils for different embodiments of the mattress of FIG. 1;

FIG. 10 illustrates various embodiments of a foam panel of the mattress of FIG. 1; and

FIG. 11 illustrates other embodiments of the mattress of FIG. 1.

DETAILED DESCRIPTION

It is to be understood that at least some of the figures and descriptions of the invention have been simplified to illustrate elements that are relevant for a clear understanding of the invention, while eliminating, for purposes of clarity, other elements that those of ordinary skill in the art will appreciate may also comprise a portion of the invention. However, because such elements are well known in the art, and because they do not facilitate a better understanding of the invention, a description of such elements is not provided herein.

FIG. 1 illustrates various embodiments of a mattress 10. For purposes of clarity, a partially exploded view of the mattress 10 is shown in FIG. 1. The mattress 10 includes a housing 12, a spring assembly 14, a quilted assembly 16, and a foam panel 18 which interlocks the spring assembly 14 and the quilted assembly 16.

FIG. 2 illustrates various embodiments of the housing 12 of the mattress 10 of FIG. 1. The housing 12 is substantially rectangular in shape, defines a receptacle 20 that is substantially rectangular in shape, having first and second ends, and also defining first and second lengths L1, L2, first and second widths W1, W2, and first and second heights H1, H2. The first length L1, the first width W1 , and the first height H1 define the respective “outer” dimensions of the housing 12. The second length L2, the second width W2, and the second height H2 define the respective “outer” dimensions of the receptacle 20. It will be appreciated that any of the first and second lengths L1 and L2, the first and second widths W1 and W2, and the first and second heights H1 and H2 can be different for different embodiments.

The housing 12 includes a panel 22 and a border 24 connected to the panel 22. The panel 22 may be fabricated from any suitable foam material. The panel 22 is substantially rectangular in shape, is fabricated to substantially the same length and width as the first length L1 and the first width W1, and has a substantially uniform thickness. The difference between the first height H1 and the second height H2 is the thickness of the panel 22.

The border 24 may be connected to the panel 22 in any suitable manner. For example, according to various embodiments, the border 24 is connected to the panel 22 with an adhesive (e.g., a glue). The border 24 may be fabricated from any suitable foam material, and is generally fabricated from the same foam material that the panel 22 is fabricated from. The border 24 is substantially uniform in cross-section also and is substantially rectangular in shape, and defines a first surface 26 and a second surface 28. The first surface 26 may be considered the “outer” surface of the border 24 and the second surface 28 may be considered the “inner” surface of the border 24. The border 24 is connected to the panel 22 such that the “outer” surface 26 of the border 24 is substantially aligned with the perimeter of the panel 22, and the “inner” surface 28 of the border 24 defines the respective “outer” dimensions of the receptacle 20, and thus defines the perimeter of the receptacle 20.

According to various embodiments, the border 24 includes a plurality of individual border members (e.g., one for each of the four sides of the rectangular shape) which are adhered together to form the entirety of the border 24. According to other embodiments, the border 24 is fabricated as a single molded component substantially rectangular in shape. According to yet other embodiments, the border 22 is fabricated as a single piece of material having a first end and a second end. The single piece of material is subsequently bent to form three corners, then the first end and the second end are adhered together to form the fourth corner of the substantially rectangular shape.

FIG. 3 illustrates various embodiments of the spring assembly 14 of the mattress 10 of FIG. 1. The spring assembly 14 is positioned on the panel 22 and within the receptacle 20, and includes a plurality of first coils 30 and a plurality of second coils 32 arranged in rows extending continuously from the first end to the second end of the receptacle. For purposes of simplicity, the panel 22 is not shown in FIG. 3. The first and second coils 30, 32 may be any suitable type of coils (e.g., bonnell coils, coil springs, etc.), and are collectively arranged to substantially cover the entire length L2 and width W2 of the receptacle 20 as shown in FIG. 4. The plurality of first and second coils 30, 32 may be arranged in any manner to substantially cover the entire length L2 and width W2 of the receptacle 20, and the respective first and second coils 30, 32 may be of any suitable size, height, shape (rectangular, cylindrical, etc.), wire gauge, composition, etc. According to various embodiments, each individual coil is positioned in a fabric pocket. All of the fabric pockets for a given “row” may be fabricated as a single “row” of pockets, and the fabric of each “row” may be connected to the fabric of adjacent “rows” by an adhesive (e.g., glue).

It will be appreciated that different embodiments of the spring assembly 14 may include different arrangements of the first and second coils 30, 32, different numbers of first coils 30, different numbers of second coils 32, different sizes (e.g., heights, wire gauges, diameters, etc.) of the first and second coils 30, 32, etc. For example, although the first and second coils 30, 32 are shown in FIG. 4 as arranged in straight lines, it will be appreciated that according to other embodiments, a “row” of either first coils 30 or second coils 32 may be arranged in a staggered or other type of configuration.

As shown in FIG. 3, the first coils 30 are of a first height and the second coils 32 are of a second height, but the first and second coils 30, 32 are otherwise identical regarding the diameter, style, metal composition, wire gauge, etc. It will be appreciated that according to other embodiments, the first and second coils 30, 32 may have different resistances to compression by being different in size, shape, style, metal composition, wire gauge, etc. In the illustrated embodiment, the first coils 30 are less resistant to compression than the second coils 32 due to the greater height of the first coils 30. A first group of the first coils 30 collectively define a first zone 34, and a first group of the second coils 32 collectively define a second zone 36. The first zone 34 is smaller than either the length L2 or the width W2 of the receptacle 20, and the second zone 36 is smaller than either the length L2 or the width W2 of the receptacle 20. The first zone 34 may be positioned anywhere on the panel 22 and within the receptacle 20, and the second zone 36 may similarly be positioned anywhere on the panel 22 and within the receptacle 20. Also, as shown in FIG. 3, each of the first and second coils 30, 32 includes a first end and a second end; and wherein the first ends of the first and second coils 30, 32 are disposed adjacent the housing panel 22 and lie in a first plane parallel to the housing panel 22. Furthermore, as shown in FIG. 3, the second ends of the first coils 30 lie in a second plane and the second ends of the second coils 32 lie in a third plane, and wherein the second plane is parallel to and spaced from the third plane.

As shown in FIG. 3, additional groups of the first coils 30 may respectively define additional first zones 34, and additional groups of the second coils 32 may respectively define additional second zones 36. For the plurality of second zones 36 shown in FIG. 3, the one in the center may be considered a torso or lumber zone 36, the one to the left may be considered a head zone 36, and the one to the right may be considered a foot or leg zone 36. In general, the first zones 34 are more firm than the second zones 36 due to the first coils 30 having greater respective heights than the second coils 32. Stated differently, the second zones 36 are more yielding than the first zones 34 due to the second coils 32 having lesser respective heights than the first coils 30.

For a given mattress 10, the number of first coils 30 which collectively define a given first zone 34 can be different than the number of first coils 30 which collectively define another first zone 34. Stated differently, the length of a given first zone 34 can be different than the length of another first zone 34. Similarly, the number of second coils 32 which collectively define a given second zone 36 can be different than the number of second coils 32 which collectively define another second zone 36. Stated differently, the length of a given second zone 36 can be different than the length of another second zone 36.

It will be appreciated that different embodiments of the mattress 10 having substantially the same size may include different arrangements of second coils 32. For example, whereas a first embodiment of the mattress 10 as shown in FIG. 5 may utilize five “rows” of second coils 32 to collectively define a second zone 36A (e.g., a head zone), seven “rows” of second coils 32 to collectively define another second zone 36B (e.g., a torso or lumbar zone), and five “rows” of second coils 32 to collectively define yet another second zone 36C (e.g., a foot or leg zone), a second embodiment of the mattress 10 as shown in FIG. 6 may utilize four “rows” of second coils 32 to collectively define a corresponding head zone 36A, nine “rows” of second coils 32 to collectively define a corresponding torso or lumbar zone 36B, and four “rows” of second coils 36 to collectively define a corresponding foot or leg zone 36C.

It will also be appreciated that different embodiments of the mattress 10 having substantially the same size may include different sizes and arrangements of first and second coils 30, 32. For example, whereas a first embodiment of the mattress 10 as shown in FIG. 7 utilizes two “rows” of first coils 30 having respective first diameters at the two ends of the spring assembly 14, a second embodiment of the mattress 10 as shown in FIG. 8 also utilizes two “rows” of first coils 30 having respective second diameters at the two ends of the spring assembly 14, and a third embodiment of the mattress 10 as shown in FIG. 9 utilizes three “rows” of first coils 30 having respective third diameters at the two ends of the spring assembly 14.

For this example, with respect to the second coils 32, the first embodiment of the mattress 10 as shown in FIG. 7 utilizes four “rows” of second coils 32 having respective first diameters to collectively define a second zone 36A (e.g., a head zone), nine “rows” of second coils 32 having respective first diameters to collectively define a second zone 36B (e.g., a torso or lumbar zone), and four “rows” of second coils 32 having respective first diameters to collectively define a second zone 36C (e.g., a foot or leg zone), the second embodiment of the mattress 10 as shown in FIG. 8 utilizes five “rows” of second coils 32 having respective second diameters to collectively define a corresponding head zone 36A, nine “rows” of the second coils 32 having respective second diameters to collectively define a corresponding torso or lumbar zone 36B, and five “rows” of second coils 32 having respective second diameters to collectively define a corresponding foot or leg zone 36C, and the third embodiment of the mattress 10 as shown in FIG. 9 utilizes five “rows” of second coils 32 having respective third diameters to collectively define a corresponding head zone 36A, eleven “rows” of second coils 32 having respective third diameters to collectively define a corresponding torso or lumbar zone 36B, and five “rows” of second coils 32 having respective third diameters to collectively define a corresponding foot or leg zone 36C.

For embodiments where the first and second coils 30, 32 are coil springs, although each of the first and second coils 30, 32 in a given embodiment had the same respective diameter, it will be appreciated that the first coils 30 of a given embodiment may include any number of different coil diameters, the second coils 32 of a given embodiment may include any number of different coil diameters, and a given embodiment may include any number of different first coil diameters and different second coil diameters.

The respective heights of the first coils 30 are substantially the same as the second height H2. Therefore, it will be appreciated that the portions of the receptacle 20 which are aligned with the first zones 34 are substantially filled by the first coils 30. As the respective heights of the second coils 32 are less than the respective heights of the first coils 30, and thus are less than the second height H2, it will be appreciated that the portions of the receptacle 20 which are aligned with the second zones 36 are not substantially filled by the second coils 32. The resulting unfilled volumes or voids 38 (see FIG. 3) are positioned directly above the second firmness zones and are collectively defined by the border 24 and the second coils 32.

FIG. 10 illustrates various embodiments of the foam panel 18 of the mattress 10 of FIG. 1. The foam panel 18 is substantially rectangular in shape, may be fabricated from any suitable material, is fabricated to substantially the same length and width as the first length L1 and the first width W1, and includes projections 40 configured to substantially fill any voids 38 (the number of projections 40 corresponds to the number of voids 38). The projections 40 are substantially rectangular in shape, are smaller than either the length L2 or the width W2 of the receptacle 20, and provide for an increased level of comfort “above” the second zones 36. Due to the projections 40, different portions of the foam assembly 18 have different respective heights. The projections 40 are connected to the spring assembly 14 and may be connected in any suitable manner. For example, according to various embodiments, the projections 40 are connected to the fabric which surrounds the second coils 32 with an adhesive (e.g., a glue). According to other embodiments, the projections 40 are connected to the fabric which surrounds the second coils 32 with a tufting. The foam panel 18 is also connected to the housing 12, and may be connected in any suitable manner. According to various embodiments, the foam panel 18 may be connected to the border 24 with an adhesive (e.g., a glue).

The foam panel 18 may be fabricated from any suitable material, and may be fabricated in any suitable manner. According to various embodiments, the foam panel 18 is fabricated from a slab of foam having a thickness equal to the largest height of the foam panel 18. Portions of the foam panel 18 which are aligned with the first zones 34 are removed from the slab to define the projections 40. According to other embodiments, the foam panel 18 is fabricated by connecting (e.g., adhering) individual foam panels which are the same size as the projections 40 to a slab of foam substantially the same length and width as the first length L1 and the first width W1 to form the foam panel 18. For such embodiments, different individual foam panels may be fabricated from different foams, and the slab of foam may be the same foam or a different foam than any one of the individual foam panels. According to yet other embodiments, the foam panel 18 may be convoluted cut to produce a plurality of “peaks” and “valleys” on a surface of the foam panel 18 (e.g., on the “upper” surface).

Returning to FIG. 1, the quilted assembly 16 is substantially rectangular in shape, and is fabricated to substantially the same length and width as the first length L1 and the first width W1. For example, the quilted assembly 16 may include a foam panel 42 substantially the same length and width as the first length L1 and the first width W1, and a quilt top 44 which covers the foam panel 42. The foam panel 42 may be fabricated from any suitable foam. For example, according to various embodiments, the foam panel is fabricated from a polyurethane foam. According to other embodiments, the foam panel 42 may include a plant based mix such as, for example, a mix which includes a soy component. It will be appreciated that the quilted assembly 16 may include any number of foam panels 42, and the respective foam panels 42 may be fabricated from the same foam or different foams.

The quilted assembly 16 is connected to the foam panel 18, and may be connected in any suitable manner. For example, according to various embodiments, the foam panel 42 is connected to the foam panel 18 with an adhesive (e.g., a glue). Due to its connection to the foam panel 18, and the connection of the foam panel 18 to the spring assembly 14, it will be appreciated that the foam panel 18 also functions to interlock the spring assembly 14 and the quilted assembly 16.

FIG. 11 illustrates other embodiments of the mattress 10 of FIG. 1. For purposes of clarity, an exploded view of the mattress 10 is shown in FIG. 11. For these embodiments, the mattress 10 also includes a foam panel 46 positioned between and connected to the quilted assembly 16 and the foam panel 18. The foam panel 46 is substantially rectangular in shape, is fabricated to substantially the same length and width as the first length L1 and the first width W1, may be fabricated from any suitable foam, and may be connected to the quilted assembly 16 and the foam panel 18 in any suitable manner. For example, according to various embodiments, the foam panel 46 may be connected to the foam panel 18 and the foam panel 42 with an adhesive (e.g., a glue).

According to other embodiments, the mattress 10 of FIG. 1 or the mattress 10 of FIG. 11 does not include the housing 12. For such embodiments, the length and width of the foam panel 18 is substantially the same as the overall length and width of the coil assembly 14, and the length and width of the quilted assembly 16 is substantially the same as the length and width of the foam panel 18. For embodiments which also include the foam panel 46, the length and width of the foam panel 46 is substantially the same as the respective lengths and widths of the foam panel 18 and the quilted assembly 16. For embodiments which do not include the housing 12, it will be appreciated that a fabric may be utilized to encapsulate the entirety of the mattress 10. It will also be appreciated that a fabric may be utilized to encapsulate the entirety of the mattress 10 for embodiments which do include the housing 12.

Nothing in the above description is meant to limit the invention to any specific materials, geometry, or orientation of elements. Many part/orientation substitutions are contemplated within the scope of the invention and will be apparent to those skilled in the art. The embodiments described herein were presented by way of example only and should not be used to limit the scope of the invention.

Although the invention has been described in terms of particular embodiments in this application, one of ordinary skill in the art, in light of the teachings herein, can generate additional embodiments and modifications without departing from the spirit of, or exceeding the scope of, the claimed invention. Accordingly, it is understood that the drawings and the descriptions herein are proffered only to facilitate comprehension of the invention and should not be construed to limit the scope thereof. 

1. A mattress, comprising: a housing, wherein the housing comprises: a panel forming a base; and a border connected to the panel, wherein the panel and border collectively define a receptacle having a first end and a second end; a spring assembly positioned on the panel and within the receptacle, wherein the spring assembly extends continuously from the first end of the receptacle to the second end of the receptacle, the spring assembly comprising a plurality of first coils and a plurality of second coils, wherein: each of the first and second coils is disposed adjacent the panel and has a first end which lies in a first plane parallel to the panel; the first coils are less resistant to compression than are the second coils; and the spring assembly defines at least three zones of firmness between the first end of the receptacle and the second end of the receptacle; a quilted assembly; and at least one foam panel disposed between the quilted assembly and the spring assembly.
 2. The mattress of claim 1, wherein the border comprises a foam material.
 3. The mattress of claim 1, wherein the border is substantially uniform in cross-section.
 4. The mattress of claim 1, wherein: the first coils are arranged in rows; and the second coils are arranged in rows.
 5. The mattress of claim 4, wherein: a first row of the first coils is positioned within the receptacle and between the first and second ends of the receptacle; a first row of the second coils is positioned within the receptacle and between the first row of the first coils and the second end of the receptacle; and a second row of the first coils is positioned within the receptacle and between the first row of the second coils and the second end of the receptacle.
 6. The mattress of claim 5, wherein a second row of the second coils is positioned between the second row of the first coils and the second end of the receptacle.
 7. The mattress of claim 1, wherein a wire gauge of the first coils is different than a wire gauge of the second coils.
 8. The mattress of claim 1, wherein a height of the first coils is greater than a height of the second coils.
 9. The mattress of claim 1, wherein a material which comprises the first coils is different from a material which comprises the second coils.
 10. The mattress of claim 1, wherein a shape of the first coils is different from a shape of the second coils.
 11. The mattress of claim 1, wherein: each of the first coils has a second end which lies in a second plane parallel to the housing panel; and each of the second coils has a second end which lies in a third plane parallel to the housing panel, wherein the second plane is parallel to and spaced from the third plane.
 12. The mattress of claim 1, wherein at least some of the second coils define at least one of the at least three zones of firmness.
 13. The mattress of claim 1, wherein the at least three zones of firmness comprise: a head firmness zone; a leg firmness zone; and a torso firmness zone between the head and leg firmness zones.
 14. The mattress of claim 1, wherein the at least one foam panel comprises a first foam panel having: a first surface adjacent a second end of the second coils; and a substantially planar second surface which lies in a second plane parallel to the housing panel.
 15. The mattress of claim 14, wherein the first foam panel is substantially uniform in cross-section.
 16. The mattress of claim 14, wherein the at least one foam panel further comprises a second foam panel disposed between the first foam panel and the quilted assembly.
 17. The mattress of claim 16, wherein the second foam panel is substantially uniform in cross-section:
 18. The mattress of claim 1, wherein the at least one foam panel has: a first surface adjacent a second end of the second coils; a second surface adjacent a second end of the first coils; and a substantially planar third surface which lies in a second plane parallel to the housing panel.
 19. The mattress of claim 1, further comprising: a first fabric pocket which surrounds one of the first coils; and a second fabric pocket which surrounds one of the second coils. 